JP2019136719A - Molding material and manufacturing method thereof - Google Patents

Abstract

To provide a molding material which can be made light in weight, has deformability without directionality and further, in addition to deformation in a tensile direction along a prescribed direction, also has sufficient deformability for a load in a compression direction.SOLUTION: A corrugated forming material 1 is constituted such that a trough part 10 and a crest part 20 along a first direction x are alternately arranged along a second direction y, at the same time, a projecting part 30 and a recessed part 40 are alternately arranged along a first direction x on the trough part 10 and the crest part 20 to constitute a corrugated shape, a connection lateral face 50 which connects a trough bottom face 11 and a crest top face 21 formed of the trough part 10 and the crest part 20 is formed, a connection lateral face 50a on the recessed part 40 of the crest part 20 is arranged at 70° with respect to the trough bottom face 11 and the crest top face 21, and a connection lateral face 50b on the projecting part 30 of the crest part 20 is arranged at 90° with respect to the trough bottom face 11 and the crest top face 21 and is smoothly changed.SELECTED DRAWING: Figure 1

Description

  The present invention relates to, for example, a molding material having a corrugated shape formed by irregularities extending in a first direction and a second direction that intersect each other, and a method for manufacturing the same.

With respect to a molding material that has been corrugated (concave and convex) on a thin plate material, molding materials having various corrugated shapes have been proposed as performance has increased and diversified.
For example, in the method for manufacturing a molding material described in Patent Document 1, a corrugated shape is formed by performing two corrugations on a metal sheet, but the direction of the second corrugation is the first By directing in an oblique direction with respect to the direction of the corrugation process, a corrugation is formed along the first direction in the unevenness extending in each of the intersecting first direction and the second direction, and an acute angle shape is formed in the uneven shape in the second direction. It is said that it is possible to form a molding material having a concave-convex shape having inner bending connection side surfaces.

  However, in the molding material proposed in the above-mentioned Patent Document 1, since the inner bent portion that forms an acute angle in the cross-sectional shape in the second direction is formed over the first direction, the deformability in the second direction and the first direction Although it is different from the deformability of the load and has sufficient deformability for the load in the pulling direction, it cannot sufficiently handle the load in the compression direction, and the deformability differs depending on the direction of the load. It was not enough to meet the current needs for diversification.

JP-T-2001-504393

  In view of the above-mentioned problems, the present invention has a deformability having no directionality, and a molding material having sufficient deformability with respect to a load in the compression direction in addition to deformation in the pulling direction along a predetermined direction, and It aims at providing the manufacturing method.

  The present invention provides a molding material having a corrugated shape formed by irregularities extending in a first direction and a second direction intersecting each other, wherein a concave valley portion and a convex shape are formed along the first direction. Are alternately arranged along the second direction, and are alternately convex along the first direction at the valleys and the peaks formed along the first direction. The corrugated shape is configured by alternately arranging portions and concave portions, and a valley bottom surface and a mountain top surface are formed in each of the valley portion and the mountain portion, and the valley bottom surface and the mountain top surface are formed. A connecting side surface to be connected is formed, the valley portion and the peak portion are formed in a wave shape in the first direction, the convex portion is formed by a wave convex portion in the wave shape, and the concave portion is a wave in the wave shape. Formed in a recess, and the peak is in front of the convex part in the peak The width in the second direction is the narrowest and the concave portion is formed in a continuous shape in which the width in the second direction is the widest, and the valley portion has a width in the second direction of the concave portion in the valley portion. The convex portion is formed in a continuous shape having the widest width in the second direction, and in the cross section in the second direction, at least the connecting side surface of the concave portion of the peak portion is the bottom surface of the valley and It is disposed at less than 90 degrees with respect to the top surface of the mountain, and at least the connecting side surface of the convex portion of the peak portion is disposed within a range of 90 degrees to 100 degrees with respect to the bottom surface of the valley and the top surface of the mountain. The connection side surface is disposed in a range of 90 degrees to 100 degrees with respect to the valley bottom surface and the mountain top surface from the concave portion disposed at less than 90 degrees with respect to the valley bottom surface and the mountain top surface. On the convex part Wherein the smoothly varying Te.

  According to the present invention, the balance between the deformability in the first direction and the deformability in the second direction is good, and in addition to the deformation in the pulling direction along the second direction, the deformation is sufficient for the load in the compression direction. The molding material which has property can be comprised.

  Specifically, at least the connection side surface in the concave portion of the peak portion is disposed at less than 90 degrees with respect to the valley bottom surface and the mountain top surface, and at least the connection side surface in the convex portion of the peak portion is the valley bottom. The connecting side surface is disposed in a range of 90 degrees or more and 100 degrees or less with respect to the surface and the top surface of the mountain, and the connection side surface is from the concave portion disposed at less than 90 degrees with respect to the bottom surface of the valley and the top surface of the mountain, Since it changes smoothly over the convex part arranged in the range of 90 degrees or more and 100 degrees or less with respect to the valley bottom face and the mountain top face, not only the deformability with respect to the load in the tensile direction but also the load in the compression direction Since it also has deformability, a molding material with high deformability in the second direction can be formed.

  Further, at least the connection side surface in the concave portion of the peak portion is disposed at less than 90 degrees with respect to the valley bottom surface and the mountain top surface, and at least the connection side surface in the convex portion of the peak portion is the valley bottom surface and The connecting side surface is disposed in a range of 90 degrees or more and 100 degrees or less with respect to the mountain top surface, and the connection side surface is formed from the concave portion disposed at less than 90 degrees with respect to the valley bottom surface and the mountain top surface. And the convex portion disposed in a range of 90 degrees or more and 100 degrees or less with respect to the top surface of the mountain is smoothly changed, that is, the angle of the connecting side surface with respect to the bottom surface of the valley and the top surface of the mountain is acute. It gradually changes from the concave part of the peak part to the convex part of the peak part that is obtuse.

In particular, in the concave portion of the peak portion having the widest width in the second direction, the connection side surface is arranged to be acute with respect to the valley bottom surface and the mountain top surface, and the width in the second direction is In the convex part of the narrowest peak part, the connecting side surface is arranged so as to be obtuse with respect to the bottom face of the valley and the top face of the peak, so that the width of the peak part in the second direction is the widest. The difference between the width in the second direction at the base portion of the connection side surface in the concave portion and the width in the second direction at the base portion of the connection side surface in the convex portion of the peak portion where the width in the second direction is the narrowest. The load in the direction intersecting the first direction and the second direction acting on the plate material can be reduced by forming a corrugated shape.
Therefore, it is possible to form a molding material having high drawability and high stretchability.

  As an aspect of the present invention, the convex portions and the concave portions that are alternately arranged along the first direction are arranged at the pitches of the valley portions and the peak portions that are alternately arranged along the second direction. The pitch may be 0.88 to 0.96 times the arrangement pitch.

  According to the present invention, the deformability in the first direction is sufficiently high with respect to the deformability in the second direction, and a molding material having a more well-balanced deformability in the first direction and the second direction is configured. can do.

  More specifically, the arrangement pitch of the valleys and the crests alternately arranged along the second direction is the arrangement of the convex parts and the depressions arranged alternately along the first direction. When formed to be 0.88 times or less with respect to the pitch, the deformability in the first direction becomes too high with respect to the deformability in the second direction, and when formed to be 0.96 times, the second The deformability in the first direction becomes too low with respect to the deformability in the direction, and the balance between the deformability in the first direction and the second direction becomes worse.

  On the other hand, the arrangement pitch of the troughs and the crests arranged alternately along the second direction is the arrangement of the convex parts and the concave parts arranged alternately along the first direction. By forming 0.88 to 0.96 times the pitch, the deformability in the first direction is sufficiently high even with respect to the deformability in the second direction, and the first direction and the second direction. In the direction, it is possible to constitute a molding material having a more well-balanced deformability.

  Moreover, as an aspect of the present invention, at least the height of the connecting side surface arranged in the range of 90 degrees or more and 100 degrees or less with respect to the bottom surface of the valley and the top surface of the mountain in the convex portion is the bottom surface of the valley and the top surface of the mountain. The width may be 0.2 to 0.6 times as large as the width.

According to the present invention, it is possible to form a molding material in which the strength and the deformability can be balanced.
More specifically, at least the height of the connecting side surface disposed in the range of 90 degrees or more and 100 degrees or less with respect to the bottom surface of the valley and the top surface of the mountain in the convex portion is the width of the bottom surface of the valley and the top surface of the mountain. On the other hand, in the case of 0.2 times or less, the height of the corrugated shape is lowered, and the strength can be secured, but the deformability is lowered. On the other hand, the height of the connecting side surface disposed in the range of 90 degrees or more and 100 degrees or less with respect to the bottom surface of the valley and the top surface of the mountain at least in the convex portion is greater than the width of the bottom surface of the valley and the top surface of the mountain. If it is 0.6 times or more, the height of the corrugated shape is increased, the strength is lowered although the deformability can be ensured.

  On the other hand, the height of the connection side surface arranged at least in the range of 90 degrees to 100 degrees with respect to the bottom surface of the valley and the top surface of the mountain in the convex portion is the width of the bottom surface of the valley and the top surface of the mountain. On the other hand, by forming from 0.2 times to 0.6 times, it is possible to form a molding material in which both strength and deformability can be balanced.

Moreover, as an aspect of this invention, you may be comprised with the metal foil materials comprised by the thickness of 0.06 mm or more and 0.10 mm or less.
According to the present invention, a local bending load by bending that has a predetermined strength and acts on the connecting side surface that is disposed at less than 90 degrees with respect to the bottom surface of the valley and the top surface of the mountain at least in the concave portion of the peak portion. Can be reduced. In addition, about the said thickness, the error below three decimal places shall be included.

As an aspect of the present invention, at least the height of the connecting side surface of the convex portion of the peak portion may be formed 10 to 30 times the thickness of the foil material.
According to the present invention, it is possible to form a molding material in which the strength and the deformability can be balanced.

  More specifically, when the height of the connecting side surface at least in the convex portion of the peak portion is 10 times or less than the thickness of the foil material, the height of the corrugated shape is lowered and the strength can be secured. The deformability of things decreases. On the contrary, when the height of the connecting side surface in the convex portion of at least the peak portion is 30 times or more with respect to the thickness of the foil material, the height of the corrugated shape is increased and the deformability can be secured. The strength of things decreases.

  On the other hand, at least the height of the connecting side surface of the convex portion of the peak portion is 10 to 30 times the thickness of the foil material, so that strength and deformability are well balanced. A compatible molding material can be formed.

Moreover, as an aspect of the present invention, the corners of the bottom surface of the valley and the top surface of the mountain and the connecting side surface may be configured with a bending radius of 2.5 times to 8.0 times the thickness of the foil material. Good.
According to this invention, while having sufficient deformability, it is hard to damage and can form a durable molding material.

  More specifically, when the corners between the bottom surface of the valley and the top surface of the mountain and the connecting side surface have a bending radius of 2.5 times or less of the material thickness, a load due to a difference in curvature between the bending inner side and the bending outer side is applied. If the bending radius is 8.0 times or more, the ratio of the corners in each of the valley bottom surface and the top surface of the mountain and the connection side surface increases, and the deformability may be reduced. There is.

  On the other hand, the corners of each of the valley bottom surface and the top surface of the mountain and the connection side surface have a bending radius of 2.5 to 8.0 times the material thickness, so The load due to the difference in curvature with the outside can be reduced, and the proportion of the corners in each of the valley bottom surface and the mountain top surface and the connection side surface can be within a range where the deformability is not impaired, and sufficient deformability can be obtained. In addition to being provided, it is possible to form a durable molding material that is not easily damaged.

As an aspect of the present invention, the foil material may be 304 stainless steel or 430 stainless steel.
According to the present invention, a more durable molding material can be formed.

  More specifically, 304 stainless steel has higher material strength and higher extensibility than other general metal foil materials, so that other general metal foils can be used to form corrugated shapes. A desired corrugated shape can be formed without being damaged even when processing is performed with a high load that is damaged by the material.

  In addition, 304 stainless steel, which has a higher material strength than other general metal foil materials, may not be able to obtain the desired deformation of a so-called spring back due to uneven processing. The desired corrugated shape can be formed without being damaged by performing the uneven processing in consideration.

  On the other hand, if 304 stainless steel is subjected to a large deformation process, it may partially magnetize and the durability may be lowered. However, since the corrugated shape is formed on the 304 stainless steel by the above uneven processing, the stainless steel foil Since the deformation performance as a material is improved, a more highly durable molding material can be configured without being magnetized even when subjected to a large deformation process.

  More specifically, 430 stainless steel is a ferritic stainless steel, has magnetism, is not hardened by heat treatment, has excellent toughness, formability and weldability, and has good workability. Moreover, it is inexpensive and can stably supply a high-quality stainless steel foil material. Although the embrittlement temperature is around 475 ° C., for example, even when a cover body, which will be described later, is used for a heat insulator of an exhaust manifold that rises to about 900 ° C., the cover body is not more than the embrittlement temperature. Therefore, the cover body having good durability can be configured without being embrittled.

As an aspect of the present invention, a plurality of the foil materials may be laminated.
According to the present invention, a molding material having a heat shielding property can be configured by improving the strength and temporarily interposing an air layer therebetween.

  Further, the plurality of the laminated foil materials are disposed at an angle of less than 90 degrees with respect to the bottom surface of the valley and the top surface of the mountain, that is, the mountain is disposed at an acute angle with respect to the bottom surface of the valley and the top surface of the mountain. It can connect by what is called a caulking effect | action by the said connection side surface in the said recessed part of a part.

  The connection side surface arranged at an acute angle with respect to the bottom surface of the valley and the top surface of the mountain is the concave portion of the peak portion, and the connection side surface of the convex portion corresponds to the bottom surface of the valley and the top surface of the mountain. It is arrange | positioned in the range of 90 degree | times or more and 100 degrees or less, and it cannot obtain the connection effect | action of the said foil materials by arrange | positioning at acute angle shape. That is, the foil members are connected by a caulking action at the concave portion in the peak portion, and are not connected at other portions. Therefore, when the foil materials are connected to each other from the concave portion to the convex portion as a whole, the difference in curvature between the foil materials when the molding material is bent and three-dimensionally processed becomes resistance to bending, Although the bending workability is lowered, the foil materials are connected by caulking action at the concave portion in the peak portion, but are not connected at other portions, so the foil material is caused by caulking action at the concave portion. While preventing each other from separating, it is possible to suppress a decrease in bending workability as described above in bending work.

As an aspect of the present invention, the foil material may be a colored foil material having a colored surface.
According to the present invention, it is possible to configure a molding material having a heat shielding property capable of shielding the radiated heat.

As an aspect of the present invention, a plurality of through holes may be provided at predetermined intervals in the foil material.
According to the present invention, it is possible to configure a molding material that can exhibit vibration damping properties, sound insulation properties, and sound absorption properties.

In addition, the present invention is a cover body that is made of the above-described molding material and is processed into a three-dimensional shape corresponding to the shape of the target member.
By this invention, the lightweight cover body formed in the three-dimensional shape suitable for the shape of the object member can be comprised from the highly deformable molded object.

  The present invention provides a molding material having a deformability having no directionality and having a sufficient deformability against a load in the compression direction in addition to a deformation in a pulling direction along a predetermined direction, and a method for manufacturing the same. be able to.

The perspective view of a molding material. The top view of a molding material. Explanatory drawing by sectional drawing of a molding material. Explanatory drawing by the expanded sectional view of the 2nd direction of a molding material. Explanatory drawing explaining the manufacturing method of a molding material. The perspective view of the heat insulator comprised with the molding material.

An embodiment of the present invention will be described below with reference to the drawings.
1 is a perspective view of the corrugated molding material 1, FIG. 2 is a plan view of the corrugated molding material 1, FIG. 3 is an explanatory view of the corrugated molding material 1, and FIG. 4 is a corrugated molding material. The explanatory view by the expanded sectional view of the 2nd direction of 1 is shown.

  Specifically, FIG. 3 (a) shows an AA cross-sectional view in FIG. 2, FIG. 3 (b) shows a BB cross-sectional view in FIG. 2, and FIG. 3 (c) shows a CC cross-section in FIG. FIG. 3D is a cross-sectional view taken along the line DD in FIG. FIG. 4A shows an enlarged view of a portion in FIG. 3A, and FIG. 4B shows an enlarged view of the portion b in FIG. 3B.

  Further, FIG. 5 shows an explanatory view for explaining a method for manufacturing the corrugated molding material 1, and FIG. 6 shows a perspective view of a heat insulator 300 constituted by the corrugated molding material 1.

  More specifically, FIG. 5A shows a perspective view of the stainless steel foil material 100 before processing, and FIG. 5B shows a one-way wave in which the corrugation 111 is formed by subjecting the stainless steel foil material 100 to the first corrugation. FIG. 5C shows a perspective view of the corrugated molding material 1 formed by subjecting the one-way corrugating material 110 to the second corrugating process.

  The corrugated molding material 1 shown in FIG. 1 is subjected to corrugation processing of unevenness extending in a first direction x and a second direction y perpendicular to the plane direction on a stainless foil material 100 (see FIG. 5). It is a molding material in which a corrugated shape constituted by unevenness extending in the direction x and the second direction y is formed. Specifically, the corrugated molding material 1 is configured by forming the corrugated shape on a foil material made of 304 stainless steel (hereinafter referred to as 304 stainless steel foil) having a thickness t of 0.08 mm.

  The corrugated shape formed on the corrugated molding material 1 will be described in detail. The concave valley portions 10 and the convex mountain portions 20 formed along the first direction x are alternately arranged along the second direction y. In addition, the corrugated shape is formed by alternately arranging the convex portions 30 and the concave portions 40 along the first direction x in the valley portions 10 and the peak portions 20 formed along the first direction x. Has been.

  The convex portion 30 is a corrugated wave convex portion, the concave portion 40 is formed by a corrugated wave concave portion, the width of the convex portion 30 in the peak portion 20 in the second direction y is the narrowest, and the trough portion 10. The width of the concave portion 40 in the valley portion 10 is the narrowest in the second direction y, and the width of the convex portion 30 in the second direction y is the widest. It is formed in a continuous shape.

  In addition, a valley bottom surface 11 is formed in the valley portion 10, a mountain top surface 21 is formed in the mountain portion 20, and connection side surfaces 50 (50 a, 50 b) that connect the valley bottom surface 11 and the mountain top surface 21 are formed. In other words, in the cross section in the second direction y, the valley portion 10 is formed in a substantially square concave shape with the valley bottom surface 11 and the connecting side surfaces 50 (50a, 50b) on both sides of the second direction y, and the peak portion 20 is 21 and the connecting side surfaces 50 (50a, 50b) on both sides in the second direction y are formed in a substantially square reverse concave shape.

  More specifically, as shown in FIGS. 3A and 4A, in the cross section in the second direction y, the connection side surface 50a of the convex portion 30 of the connection side surface 50 is connected to the mountain top surface 21 or the valley bottom surface 11. The angle Ra (Ra1, Ra2) of the formed angle 60a (61a, 62a) is formed at approximately 90 ° in the range of 90 ° to 100 °.

  3B and FIG. 4B, in the cross section in the second direction y, an angle 60b formed by the connection side surface 50b of the concave portion 40 of the connection side surface 50 and the mountain top surface 21 or the valley bottom surface 11 is formed. The angle Rb (Rb1, Rb2) of (61b, 62b) is formed at approximately 70 ° which is less than 90 °.

  And in the convex part 30, it was formed at the connection side surface 50a formed at about 90 degrees with respect to the mountain top surface 21 or the valley bottom surface 11, and at the concave part 40 formed at about 70 degrees with respect to the mountain top surface 21 or the valley bottom surface 11. The connection side surface 50b is continuously formed while smoothly changing the angle 60 formed with the mountain top surface 21 or the valley bottom surface 11.

  Note that the bending radius ra (ra1, ra2) at the corner 60a where the angle Ra formed by the crest top surface 21 or the trough bottom surface 11 and the connecting side surface 50a in the convex portion 30 is approximately 90 ° constitutes the corrugated molding 1 304. The thickness t of the stainless steel foil is 0.4 mm (5.0 times) out of the range of 0.2 mm to 0.6 mm that is 2.5 times to 7.5 times 0.08 mm.

  In addition, the bending radius rb (rb1, rb2) at the corner 60b where the angle Rb formed between the top surface 21 or the bottom surface 11 and the connecting side surface 50b in the concave portion 40 is approximately 90 ° is 304 stainless steel constituting the corrugated molding 1. The foil thickness t is 2.0 mm in the range of 0.8 mm to 2.4 mm, which is 2.5 to 8.0 times 0.08 mm.

  Moreover, the connection side surface 50a in the convex part 30 is in the range of 0.8 mm to 2.4 mm which is 0.2 to 0.6 times the width w of the top surface 21 or the bottom surface 11 of 4.0 mm. Of these, the height H is 2.0 mm, and the thickness t of 304 stainless steel foil is 25.0 times in a range of 10 to 30 times 0.08 mm.

  In the corrugated shape formed with such a cross-sectional shape, as shown in FIG. 2, the arrangement pitch Py of the valley portions 10 and the mountain portions 20 alternately arranged along the second direction y is 11.74 mm. Arrangement pitch Px of convex portions 30 and concave portions 40 alternately arranged along one direction x: 0.92 times out of a range of 0.88 to 0.96 times with respect to 12.75 mm. Yes.

  For example, as shown in FIG. 6, the corrugated molding material 1 configured in this way is pressed into a three-dimensional shape corresponding to the shape of a target member such as an exhaust manifold (hereinafter referred to as “exhaust manifold”) or a catalyst, and the heat insulator 300. Can be configured.

  As shown in FIG. 5, the corrugated molding material 1 having such a configuration uses a pair of corrugating rollers (not shown), and a stainless foil material is passed between the corrugating rollers so as to have a corrugated 111. 110, the direction of the one-way corrugating material 110 is rotated 90 degrees in the plan view direction, and then passed between the corrugating rollers to produce the corrugated molding material 1.

  The corrugated roller can adjust the gear tooth crest angle and the interval in the opposite direction, and the corrugated shape described above is formed by adjusting these in the first corrugation process and the second corrugation process. The corrugated molding material 1 made can be manufactured.

  Moreover, as a manufacturing method of the corrugated molding 1, not only the manufacturing method using the above-described pair of corrugating rollers, but also a pair of presses (not shown) in which a plurality of waveforms in a predetermined direction are arranged in parallel in the intersecting direction, for example. Used, by pressing the stainless steel foil material 100 to form a one-way corrugating material 110 having a corrugation 111, and by performing a second press working in a direction crossing the one-way corrugating material 110. The corrugated molding 1 may be manufactured by forming the corrugated shape described above.

Further, a unidirectional wave having a waveform 111 is formed using a processing device that forms a waveform by pressing a pair of corrugated members arranged at an appropriate interval in a predetermined direction from both sides of the stainless steel foil material 100 moving in a predetermined direction. The corrugated molding material 1 may be manufactured by forming the corrugated material 110 and forming the corrugated shape by the second pressing while moving the one-way corrugating material 110 in a predetermined direction toward the intersecting direction. .
Thus, the manufacturing method of the corrugated molding 1 is not limited to the manufacturing method using a pair of corrugating rollers, and can be manufactured by various manufacturing methods.
Therefore, it is possible to form a molding material having high drawability and high stretchability.

  As described above, the corrugated molding material 1 having the corrugated shape formed by the unevenness extending in the intersecting first direction x and the second direction y is a concave valley formed along the first direction x. The portions 10 and the convex ridges 20 are alternately arranged along the second direction y, and the valleys 10 and the ridges 20 formed along the first direction x are arranged along the first direction x. The convex portions 30 and the concave portions 40 are alternately arranged to form a corrugated shape, and a valley bottom surface 11 and a mountain top surface 21 are formed in each of the valley portion 10 and the mountain portion 20, and the valley bottom The connection side surface 50 (50a, 50b) which connects the surface 11 and the crest upper surface 21 is formed, the trough part 10 and the crest part 20 are formed in the waveform of the 1st direction x, and the convex-shaped part 30 is the waveform convexity of a waveform. The concave portion 40 is formed by a corrugated wave concave portion, and the peak portion 2 is formed. Is formed in a continuous shape in which the width w in the second direction y of the convex portion 30 in the peak portion 20 is the smallest and the width w in the second direction y of the concave portion 40 is the largest. In the portion 10, the concave portion 40 is formed in a continuous shape in which the width w in the second direction y is the smallest and the width w in the second direction y of the convex portion 30 is the largest. The connection side surface 50b in the portion 40 is disposed at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21, and the connection side surface 50a in the convex portion 30 is 90 degrees to 100 degrees with respect to the valley bottom surface 11 and the mountain top surface 21. The connecting side surfaces 50 (50 a, 50 b) are disposed in a range from the concave portion 40 disposed at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21, and 90 with respect to the valley bottom surface 11 and the mountain top surface 21. Arranged in the range of 100 degrees or more It is smoothly changed toward the convex portion 30.

  Therefore, the balance between the deformability in the first direction x and the deformability in the second direction y is good, and in addition to the deformation in the pulling direction along the second direction y, sufficient deformability is also obtained for the load in the compression direction. The corrugated molding material 1 which has can be comprised.

  More specifically, the connecting side surface 50b in the concave portion 40 is disposed at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21, and the connecting side surface 50a in the convex portion 30 is 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21. The connecting side surface 50 (50a, 50b) is disposed within the range of 100 degrees or less and the valley bottom surface 11 and the mountain top surface from the concave portion 40 disposed at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21. Since it changes smoothly over the convex part 30 arranged in the range of 90 degrees or more and 100 degrees or less with respect to 21, not only the deformability with respect to the load in the tensile direction but also the deformability with respect to the load in the compression direction is provided. Therefore, the corrugated molding material 1 having high deformability in the second direction y can be configured. Therefore, it is possible to form a molding material having high drawability and high stretchability.

  Further, the connecting side surface 50b in the concave portion 40 is disposed at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21, and the connecting side surface 50a in the convex portion 30 is 90 degrees to 100 degrees with respect to the valley bottom surface 11 and the mountain top surface 21. The connecting side surfaces 50 (50a, 50b) are arranged on the valley bottom surface 11 and the mountain top surface 21 from the concave portions 40 arranged at less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21. On the other hand, it changes smoothly over the convex part 30 arrange | positioned in the range of 90 degree | times or more and 100 degrees or less, that is, the angle with respect to the valley bottom face 11 and the mountain top face 21 of the connection side surface 50 (50a, 50b) is acute-angle shape. It gradually changes from the concave portion 40 of a certain peak 20 to the convex portion 30 of the peak 20 having an obtuse angle.

  In particular, the connecting side surface 50 (50a, 50b) is disposed so as to have an acute angle with respect to the valley bottom surface 11 and the mountain top surface 21 in the concave portion 40 of the peak portion 20 having the widest width w in the second direction y. Since the connecting side surface 50 (50a, 50b) is arranged to be obtuse with respect to the bottom surface 11 and the top surface 21 of the convex portion 30 of the peak portion 20 having the narrowest width w in the two directions y, the first The width w in the second direction y at the base of the connecting side surface 50b of the concave portion 40 of the peak 20 having the widest width w in the two directions y and the convex portion 30 of the peak 20 having the narrowest width w in the second direction y. The difference between the width w in the second direction y at the base portion of the connecting side surface 50a in the sheet can be reduced, and the load in the direction intersecting the first direction x and the second direction y acting on the plate material can be reduced by forming a corrugated shape. be able to.

  Note that the arrangement pitch Py of the valleys 10 and the peaks 20 alternately arranged along the second direction y is the arrangement pitch of the convex parts 30 and the concave parts 40 arranged alternately along the first direction x. Since it is formed to be 0.92 times in the range of 0.88 to 0.96 times with respect to Px, the deformability in the first direction x is sufficiently high with respect to the deformability in the second direction y. In the first direction x and the second direction y, it is possible to configure the corrugated molding material 1 having further balanced deformability.

  More specifically, the arrangement pitch Py of the valleys 10 and the peaks 20 alternately arranged along the second direction y is the same as that of the convex parts 30 and the concave parts 40 arranged alternately along the first direction x. When formed at 0.88 times or less with respect to the arrangement pitch Px, the deformability in the first direction x becomes too high compared to the deformability in the second direction y, and when formed at 0.96 times, The deformability in the first direction x is too low relative to the deformability in the two directions y, and the balance between the deformability in the first direction x and the second direction y is deteriorated.

  On the other hand, the arrangement pitch Py of the valleys 10 and the peaks 20 alternately arranged along the second direction y is equal to that of the convex parts 30 and the concave parts 40 arranged alternately along the first direction x. By forming 0.88 to 0.96 times the arrangement pitch Px, the deformability in the first direction x is sufficiently high with respect to the deformability in the second direction y. In the two directions y, it is possible to configure the corrugated molding material 1 having further balanced deformability.

  Further, the height H of the connecting side surface 50a arranged in the range of 90 degrees or more and 100 degrees or less with respect to the valley bottom surface 11 and the mountain top surface 21 at least in the convex portion 30 is the width w of the valley bottom surface 11 and the mountain top surface 21. On the other hand, since it is formed 0.2 to 0.6 times, it is possible to form the corrugated molded material 1 in which the strength and the deformability can be balanced.

  More specifically, the height H of the connecting side surface 50a arranged in the range of 90 degrees to 100 degrees with respect to the valley bottom surface 11 and the mountain top surface 21 at least in the convex portion 30 is the width of the valley bottom surface 11 and the mountain top surface 21. In the case of 0.2 times or less with respect to w, the height of the corrugated shape is lowered, and although the strength can be ensured, the deformability is lowered. On the other hand, the height H of the connecting side surface 50a arranged in the range of 90 degrees or more and 100 degrees or less with respect to the valley bottom surface 11 and the mountain top surface 21 at least in the convex portion 30 is the width w of the valley bottom surface 11 and the mountain top surface 21. In contrast, when the ratio is 0.6 times or more, the height of the corrugated shape is increased, and although the deformability can be ensured, the strength is decreased.

  On the other hand, the height H of the connection side surface 50a arranged in the range of 90 degrees or more and 100 degrees or less with respect to the valley bottom surface 11 and the mountain top surface 21 at least in the convex portion 30 is the width of the valley bottom surface 11 and the mountain top surface 21. By forming 0.2 to 0.6 times w, it is possible to form the corrugated molding material 1 in which both strength and deformability can be balanced.

  Moreover, since it is comprised with the metal stainless steel foil material 100 whose thickness t is 0.08 mm among the range of 0.06 mm or more and 0.10 mm or less, while having predetermined intensity | strength, in the recessed part 40, the valley bottom face 11 And the local bending load by the bending which acts on the connection side surface 50b arrange | positioned with respect to the mountain top surface 21 at less than 90 degree | times can be made small.

  Moreover, since the height H of the connection side surface 50a in the convex-shaped part 30 is formed in 2.0 mm in the range of 10 times thru | or 30 times with respect to the thickness t of the stainless steel foil material 100, strength and deformability Therefore, it is possible to form the corrugated molding material 1 that can balance both in a balanced manner.

  More specifically, when the height H of the connecting side surface 50a in the convex portion 30 is 10 times or less than the thickness t of the stainless steel foil material 100, the corrugated shape is lowered and the strength can be ensured, but the deformability. Decreases. Conversely, when the height H of the connecting side surface 50a in the convex portion 30 is 30 times or more the thickness t of the stainless steel foil material 100, the height of the corrugated shape is increased, and the strength of the deformability can be ensured. descend.

  On the other hand, the height H of the connecting side surface 50a in the convex portion 30 is 10 times to 30 times the thickness t of the stainless steel foil material 100, so that the corrugation can balance strength and deformability in a balanced manner. The molding material 1 can be formed.

  Further, the corner 60a between each of the valley bottom surface 11 and the mountain top surface 21 and the connecting side surface 50a is configured with a bending radius ra that is 2.5 to 8.0 times the thickness t of the stainless steel foil material 100. Thus, the corrugated molding material 1 can be configured which has excellent deformability, is hardly damaged, and is durable.

  More specifically, when the corner 60a between each of the valley bottom surface 11 and the mountain top surface 21 and the connecting side surface 50a has a bending radius ra of 2.5 times or less of the thickness t, the load due to the difference in curvature between the bending inner side and the bending outer side. If the bend radius ra is 8.0 times or more, the ratio of the corner 60a in each of the valley bottom surface 11 and the mountain top surface 21 to the connection side surface 50a increases, and the deformability decreases. There is a risk.

  On the other hand, the corner 60a between each of the valley bottom surface 11 and the mountain top surface 21 and the connecting side surface 50a has a bending radius ra that is 2.5 to 8.0 times the thickness t, so The load caused by the difference in curvature from the outer side of the bend can be reduced, and the ratio of the corner 60a in each of the valley bottom surface 11 and the mountain top surface 21 and the connecting side surface 50a can be set within a range in which the deformability is not impaired. In addition, the corrugated molding material 1 which is not easily damaged and has durability can be configured.

Moreover, since the stainless steel foil material 100 is 304 stainless steel, the highly durable corrugated molding material 1 can be comprised.
More specifically, 304 stainless steel has higher material strength and higher extensibility than other general metal foil materials, so that other general metal foils can be used to form corrugated shapes. A desired corrugated shape can be formed without being damaged even when processing is performed with a high load that is damaged by the material.

  In addition, 304 stainless steel, which has a higher material strength than other general metal foil materials, may not be able to obtain the desired deformation of a so-called spring back due to uneven processing. The desired corrugated shape can be formed without being damaged by performing the uneven processing in consideration.

  On the other hand, if 304 stainless steel is subjected to a large deformation process, it may partially magnetize and the durability may be lowered. However, since the corrugated shape is formed on the 304 stainless steel by the above uneven processing, the stainless steel foil Since the deformation performance as the material 100 is improved, the corrugated molding material 1 having higher durability can be configured without being magnetized even when subjected to a large deformation process.

  In addition, as described above, the heat insulator 300 that is configured by the corrugated molding material 1 and processed into a three-dimensional shape corresponding to the shape of the target member has a three-dimensional shape suitable for the shape of the target member. The formed weight can be reduced.

In correspondence between the configuration of the present invention and the above-described embodiment,
The first direction of the invention corresponds to the first direction x, and so on.
The second direction corresponds to the second direction y,
The valley corresponds to the valley 10
The mountain corresponds to the mountain 20
The convex part corresponds to the convex part 30,
The concave portion corresponds to the concave portion 40,
The connecting side surface corresponds to the connecting side surface 50 (50a, 50b),
The molding material corresponds to corrugated molding material 1,
The mountain pitch corresponds to the pitch Py,
The arrangement pitch of the concave portions corresponds to the arrangement pitch Px,
The valley bottom corresponds to the valley bottom 11,
The top surface of the mountain corresponds to the top surface 21 of the mountain,
The width corresponds to the width w
The foil material corresponds to the stainless steel foil material 100,
The corner corresponds to the corner 60a,
The bending radius corresponds to the bending radius ra,
The cover body corresponds to the heat insulator 300,
The present invention is not limited only to the configuration of the above-described embodiment, and many embodiments can be obtained.

  For example, the metal stainless steel foil material 100 is not limited to the above-described thickness t: 0.08 mm as long as the thickness t is 0.10 mm or less. For example, when the stainless steel foil material 100 having a thickness t of 0.08 mm is used, the bending radius ra (ra1, ra2) is 2.5 of the 304 stainless steel foil constituting the corrugated molding material 1 having a thickness t of 0.08 mm. It is formed in the range of 0.20 mm to 0.65 mm that is in the range of double to 8.0 times, but as an example, it is formed in the range of 0.57 mm.

  In addition, the corrugated shape may be a so-called corrugated shape or embossed shape in which an elliptical shape, a hemispherical shape, a frustum shape, and the like are arranged in a direction intersecting each other, without looking at the above shape.

  Moreover, you may laminate | stack the several stainless steel foil material 100, and while improving intensity | strength, the corrugated molding material 1 which has heat insulation can be comprised by interposing an air layer in between.

  Further, a plurality of laminated stainless steel foil materials 100 are disposed at an angle of less than 90 degrees with respect to the valley bottom surface 11 and the mountain top surface 21, that is, a mountain disposed at an acute angle with respect to the valley bottom surface 11 and the mountain top surface 21. The connecting side surface 50b in the concave portion 40 of the portion 20 can be connected by a so-called caulking action.

  The connecting side surface 50b disposed at an acute angle with respect to the valley bottom surface 11 and the mountain top surface 21 is the concave portion 40 of the peak portion 20, and the connection side surface 50a in the convex portion 30 is on the valley bottom surface 11 and the mountain top surface 21. On the other hand, it arrange | positions in 90 degrees or more and 100 degrees or less, and cannot obtain the connection effect | action of the stainless steel foil materials 100 by arrange | positioning at acute angle | corner shape. That is, the stainless steel foil materials 100 are connected by the caulking action at the concave portion 40 in the peak portion 20 and are not connected at other portions. Therefore, when the stainless steel foil materials 100 are connected to each other from the concave portion 40 to the convex portion 30, there is a difference in curvature between the stainless steel foil materials 100 when the corrugated molding material 1 is bent and three-dimensionally processed. Although it becomes resistance to bending and bending workability is lowered, although the stainless steel foil materials 100 are connected to each other by the caulking action at the concave portion 40 in the peak portion 20, the other portions are not connected. While preventing the stainless steel foil materials 100 from being separated from each other by the caulking action, it is possible to suppress a decrease in the bending workability as described above in the bending work.

The stainless steel foil material 100 may be a colored stainless steel foil material 100 having a colored surface, whereby the corrugated molding material 1 having a heat shielding property capable of shielding the radiated heat can be configured. .
Further, a plurality of through holes may be provided at predetermined intervals in the stainless steel foil material 100, and the corrugated molding material 1 that can exhibit vibration damping properties, sound insulation properties, and sound absorption properties can be configured.

  In the above description, 304 stainless steel is used as the stainless steel foil material 100. However, 430 stainless steel may be used, and the highly durable corrugated molding material 1 can be configured.

More specifically, 430 stainless steel is a ferritic stainless steel, has magnetism, is not hardened by heat treatment, has excellent toughness, formability and weldability, and has good workability. Moreover, it is inexpensive and can stably supply the high-quality stainless steel foil material 100. Although the embrittlement temperature is around 475 ° C, the heat insulator 300 attached to the exhaust manifold that rises to around 900 ° C only rises to a temperature below the embrittlement temperature. A heat insulator with good characteristics can be configured.
Moreover, you may comprise not only the stainless steel foil material 100 but other metal foil materials, such as the product made from aluminum, the product made from an aluminum alloy, and may comprise the metal plate material of the thickness and intensity | strength which can comprise the above-mentioned corrugated shape. .

DESCRIPTION OF SYMBOLS 1 ... Corrugated molding material 10 ... Valley part 11 ... Valley bottom surface 20 ... Mountain part 21 ... Mountain top surface 30 ... Convex part 40 ... Concave part 50 (50a, 50b) ... Connection side surface 60a ... Corner 100 ... Stainless steel foil material 300 ... Heat Insulator r ... Bending radius Py ... Arrangement pitch Px ... Arrangement pitch x ... First direction y ... Second direction w ... Width

Claims (11)

It is a molding material in which a corrugated shape constituted by irregularities extending in the intersecting first direction and the second direction is formed,
While the concave valleys and the convex peaks formed along the first direction are alternately arranged along the second direction,
The corrugated shape is configured by alternately arranging convex portions and concave portions along the first direction in the valley portion and the mountain portion formed along the first direction,
A valley bottom surface and a mountain top surface are formed in each of the valley portion and the mountain portion, and a connecting side surface that connects the valley bottom surface and the mountain top surface is formed,
The valley and the peak are formed in a waveform in the first direction,
The convex portion is formed by the corrugated wave convex portion, and the concave portion is formed by the corrugated wave concave portion,
The peak portion is formed in a continuous shape in which the width in the second direction of the convex portion in the peak portion is the smallest and the width in the second direction of the concave portion is the largest.
The trough is formed in a continuous shape in which the width of the concave portion in the trough is narrowest in the second direction and the width of the convex portion in the second direction is widest,
In the cross section in the second direction,
At least the connection side surface in the concave portion of the peak portion is disposed at less than 90 degrees with respect to the valley bottom surface and the mountain top surface, and at least the connection side surface in the convex portion of the peak portion is the valley bottom surface and the peak. While being arranged in the range of 90 degrees or more and 100 degrees or less with respect to the upper surface,
The connecting side surface is
Smoothly from the concave portion arranged at less than 90 degrees with respect to the bottom surface of the valley and the top surface of the mountain to the convex portion arranged within a range of 90 degrees to 100 degrees with respect to the bottom surface of the valley and the top surface of mountain. Molding material that changes into The arrangement pitch of the valleys and the peaks arranged alternately along the second direction,
2. The molding material according to claim 1, wherein the molding material is formed to be 0.88 to 0.96 times the arrangement pitch of the convex portions and the concave portions alternately arranged along the first direction. At least the height of the connecting side surface arranged in the range of 90 degrees or more and 100 degrees or less with respect to the bottom surface of the valley and the top surface of the mountain in the convex portion is 0. 0 with respect to the width of the bottom surface of the valley and the top surface of the mountain. The molding material according to claim 1, wherein the molding material is formed to be 2 to 0.6 times. The molding material in any one of Claims 1 thru | or 3 comprised with the metal foil materials comprised by 0.06 mm or more and 0.10 mm or less thickness. 5. The molding material according to claim 4, wherein at least a height of the connection side surface in the convex portion of the peak portion is formed 10 to 30 times as large as a material thickness of the foil material. The corner part of each of the said valley bottom face and the said mountain top surface, and the said connection side surface was comprised by the bending radius of 2.5 to 8.0 times the material thickness of the said foil material. Molding material. The molding material according to claim 4, wherein the foil material is 304 stainless steel foil or 430 stainless steel. The molding material according to claim 4, wherein a plurality of the foil materials are laminated. The molding material according to any one of claims 4 to 8, wherein the foil material is a colored foil material having a colored surface. The molding material according to claim 4, wherein a plurality of through holes are provided at predetermined intervals in the foil material. It is comprised with the molding material in any one of Claims 1 thru | or 10,
A cover body processed into a three-dimensional shape according to the shape of the target member.

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